CA2664436C - Commutator for an electrical machine - Google Patents
Commutator for an electrical machine Download PDFInfo
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- CA2664436C CA2664436C CA2664436A CA2664436A CA2664436C CA 2664436 C CA2664436 C CA 2664436C CA 2664436 A CA2664436 A CA 2664436A CA 2664436 A CA2664436 A CA 2664436A CA 2664436 C CA2664436 C CA 2664436C
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- commutator
- recited
- solder
- segment
- winding connection
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R39/00—Rotary current collectors, distributors or interrupters
- H01R39/02—Details for dynamo electric machines
- H01R39/04—Commutators
- H01R39/045—Commutators the commutators being made of carbon
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/028—Soldered or welded connections comprising means for preventing flowing or wicking of solder or flux in parts not desired
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/06—Manufacture of commutators
- H01R43/08—Manufacture of commutators in which segments are not separated until after assembly
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Motor Or Generator Current Collectors (AREA)
Abstract
The invention relates to a commutator (1) with contact segments (9), arranged at a distance from each other and forming a brush running surface (5), each of which is soldered to a fixing section (5) of a metal segment support piece (4) and with a hub body (3) made from an electrically insulating material which supports the segment support pieces (9) each of which are provided with a winding connector hook (7). According to the invention, at least one solder barrier recess (16) is provided in the upper side of the fixing section (5) facing the contact segment (9) and/or in the under side of the contact segment (4) facing the fixing section (5).
Description
Description Title COMMUTATOR FOR AN ELECTRICAL MACHINE
Background Information The present invention relates to a commutator according to the preamble of claim 1.
A hook commutator for an electric motor armature is made known in WO 02/19478 Al.
The known commutator includes a plurality of interspaced metallic segment support pieces, each of which includes a fastening section which is clawed into the hub body, and which is connected to a carbon contact segment in a fixed and electrically conductive manner, the contact segments forming, in sum, a brush running surface. An axial section abuts the fastening section of each segment support piece in the axial direction; a winding connection hook to which a winding wire may be electrically connected is provided on the end side of the axial section. In the process of manufacturing the electric motor armature, a winding wire is wound in each winding connection hook. The necessary process of connecting the winding wire and the winding connection hook ensures that the quality of the mechanical and electrical connection between the winding connection hook and the winding wire remains consistently high. "Hot staking" is used as the connecting process. In this process, the winding connection hook is deformed in such a manner that the winding wire becomes clamped in position. An electric voltage is then applied in order to heat the winding connection hook and the winding wire. In this process, an insulation layer detaches from the winding wire, and the winding wire and winding connection hook become welded together. It is also known from the publication to provide a region having a reduced cross-sectional surface area in the transition region between the axial section and the fastening section of the segment support piece in order to reduce the thermal conduction from the winding connection hook to the fastening section, e.g. to avoid damaging the solder connection between the contact segment and fastening section in the hot staking process.
Background Information The present invention relates to a commutator according to the preamble of claim 1.
A hook commutator for an electric motor armature is made known in WO 02/19478 Al.
The known commutator includes a plurality of interspaced metallic segment support pieces, each of which includes a fastening section which is clawed into the hub body, and which is connected to a carbon contact segment in a fixed and electrically conductive manner, the contact segments forming, in sum, a brush running surface. An axial section abuts the fastening section of each segment support piece in the axial direction; a winding connection hook to which a winding wire may be electrically connected is provided on the end side of the axial section. In the process of manufacturing the electric motor armature, a winding wire is wound in each winding connection hook. The necessary process of connecting the winding wire and the winding connection hook ensures that the quality of the mechanical and electrical connection between the winding connection hook and the winding wire remains consistently high. "Hot staking" is used as the connecting process. In this process, the winding connection hook is deformed in such a manner that the winding wire becomes clamped in position. An electric voltage is then applied in order to heat the winding connection hook and the winding wire. In this process, an insulation layer detaches from the winding wire, and the winding wire and winding connection hook become welded together. It is also known from the publication to provide a region having a reduced cross-sectional surface area in the transition region between the axial section and the fastening section of the segment support piece in order to reduce the thermal conduction from the winding connection hook to the fastening section, e.g. to avoid damaging the solder connection between the contact segment and fastening section in the hot staking process.
Problems always occur in the process of creating the solder connection between the carbon contact segments and the associated fastening sections. This is due to the fact that, when the solder is in the liquid state, the intermolecular adhesive forces between the liquid solder and the contact segment, and/or between the solder and the metallic fastening section are greater than the intermolecular cohesion forces within the solder.
This results in a capillary diffusion of the liquid solder in surface regions that are not wetted with the liquid solder, mainly in edge and corner regions of the carbon segment and the fastening section. In fact, hardened droplets of solder often overhang on the sides. The hardened droplets of solder partially extend over the air gap between two adjacent fastening sections, thereby resulting in dangerous electrical short circuits. It also happens that overhanging solder particles become detached during operation of the fully-assembled electrical machine, enter the region of the motor winding, and cause short circuits to happen there. Detached solder particles may also damage, e.g. a fuel pump through which fuel flows and which is equipped with the known commutator.
To prevent solder particles from overhanging on the sides, attempts were made to reduce the quantity of solder used. However, this results in an undesired, reduced robustness and reduced electrical conductivity of the connections of contact segments and the associated fastening sections.
Disclosure of the Invention Technical Object The object of an aspect of the present invention, therefore, is to provide a commutator in which droplets of solder that overhang on the sides of the fastening sections are avoided, without reducing the quantity of solder used.
Technical Solution The present invention is based on the idea of forming a recess, in particular an elongated recess in the fastening section of the segment support piece, which is preferably made of copper or a copper alloy, and/or in the underside of the contact segment which is preferably made of a carbon-graphite mixture, and which faces the fastening section, the recess being used as a solder barrier and preventing the solder from flowing - at least in some regions - over the circumferential edge of the fastening section or the contact segment. A solder-barrier recess of this type may easily be stamped or punched in the fastening section in the process of manufacturing the segment support piece. The depth and width of the solder-barrier recess should be sized in such a manner that a quantity of liquid solder may be accommodated that is sufficient to prevent the solder-barrier recess from overflowing.
The solder-barrier recess preferably completely limits a solder surface to be provided with solder during the connecting process. It is also feasible, however, to provide a solder-barrier recess to protect only those regions against the infusion of liquid solder that are at highest risk, in particular the air gaps which are situated in the circumferential direction between two adjacent contact segments.
If the commutator is designed as a flat commutator having a flat brush running surface, the fastening section being formed by a radial section of the segment support piece, it is advantageous to situate the solder-barrier recess at least in a radially outer region of the fastening section in order to prevent liquid solder from escaping on the circumferential side of the commutator.
To realize the largest possible solder surface and, therefore, good robustness and electrical conductivity of the connections of contact segments and fastening sections, it is provided according to an advantageous development of the present invention to situate the solder-barrier recess close to the edge on the contact segment underside, and/or on the top side of the fastening section. The solder-barrier recess is preferably designed as a trough-like recess that is closed around the circumference.
To protect the solder connection between a contact segment and the associated fastening section from the harmful effects of heat, in particular during a hot-staking process to attach a winding wire to the winding connection hook of the associated segment support piece, it is advantageously provided in an embodiment of the present invention that a thermal barrier region having a reduced cross-sectional area is provided in a region between the winding connection hook and the fastening section. By reducing the effective cross-sectional area, the heat flow from the winding connection hook is hindered in the direction toward the fastening section and, therefore, in the direction toward the solder connection, thereby advantageously preventing negative effects of the hot-staking process on the solder connection.
Advantageously, the effective cross-sectional area in the thermal barrier region is reduced by the fact that at least one recess having a curved contour, preferably at least in sections, or a closed circumference, or is open at the edge is provided in the segment support piece.
The thermal barrier region is preferably formed in the thermal barrier region between two recesses which are separated in the circumferential direction, are open at the edges, and, in particular, are open and curved inward, thereby making only this small cross-sectional surface area available for heat flow in the direction toward the fastening section. Advantageously, the extension of the thermal barrier region in the circumferential direction at least approximately corresponds to the extension of the winding connection hook in the circumferential direction.
An expedient development of the present invention provides even better thermal protection. A metallic punched-bent part which is made of copper in particular, and which includes adjacent segment support pieces in the circumferential direction are used to manufacture the commutator. A solder-barrier recess is preferably provided in each of these segment support pieces. Every segment support piece includes a winding connection hook and a fastening section for fixing a contact segment. Every two adjacent segment support pieces are connected to one another via a segment which is oriented in the circumferential direction and is preferably curved. Otherwise, only an air gap is situated between the adjacent segment support pieces. As a whole, all of the segments form a connection having an annular shape. According to the present invention, it is now provided that this annular connection is situated as far as possible from the winding connection hooks, preferably in the region of the exposed end of the fastening sections that are far from the winding connection hooks. The situation is as 5 follows. As the manufacture of the commutator continues, in a first step, a contact disk is soldered to the fastening sections. Next, the component which is composed of the metallic punched-bent part and the contact disk which is preferably composed of carbon or a carbon-graphite mixture is partially covered, via injection molding with a coating of an insulating material, preferably a pressed material, in particular a duroplast with reinforcing element such as glass fibers or glass fiber beads. The metallic sides of the segment support pieces that face one another are also provided with a coating applied via injection molding. To electrically insulate the segment support pieces from one another, in a subsequent step, the contact disk must be subdivided into individual contact segments. Moreover, all connecting segments between the segment support pieces must be removed. This is carried out, e.g. in a sawing process in which the width of the saw or the saw blade is preferably smaller than the air gap between two adjacent segment support pieces. After the connecting segments are separated, two exposed metal surfaces remain on each segment support piece, which are not insulated against the hub body, and via which heat may "flow into" the segment support piece or its fastening section particularly easily, thereby negatively affecting the solder connection to the associated contact segment. Due to the largest possible separation, according to the present invention, of the connecting segments (and, therefore, the exposed metal surfaces) from the winding connection hooks which are heating during the hot-staking process, a minimal quantity of heat is introduced into the associated fastening section via these exposed areas, which advantageously affects the solder connection between the fastening section and the contact segment.
The present invention relates not only to the fully-assembled commutator, but also to the annular punched-bent part which is made of copper or a copper alloy in particular, and its manufacture, in which the connecting segments between the individual segment support pieces are situated as far as possible from the winding connection hooks.
5a In accordance with an aspect of the invention, there is provided a commutator comprising interspaced contact segments which form a brush running surface, each contact segment being soldered to a fastening section of a metallic segment support piece, and comprising a hub body composed of an electrically insulating material which supports the interspaced segment support pieces, each of which is provided with a winding connection hook, wherein at least one solder-barrier recess is formed in at least one of (a) an upper side of at least one of the fastening sections and facing one of the contact segments, and (b) an underside of at least one of the contact segments and facing one of the fastening sections and wherein the solder barrier recess extends at least approximately in a circumferential direction and is situated axially between a solder surface and the winding connection hook.
This results in a capillary diffusion of the liquid solder in surface regions that are not wetted with the liquid solder, mainly in edge and corner regions of the carbon segment and the fastening section. In fact, hardened droplets of solder often overhang on the sides. The hardened droplets of solder partially extend over the air gap between two adjacent fastening sections, thereby resulting in dangerous electrical short circuits. It also happens that overhanging solder particles become detached during operation of the fully-assembled electrical machine, enter the region of the motor winding, and cause short circuits to happen there. Detached solder particles may also damage, e.g. a fuel pump through which fuel flows and which is equipped with the known commutator.
To prevent solder particles from overhanging on the sides, attempts were made to reduce the quantity of solder used. However, this results in an undesired, reduced robustness and reduced electrical conductivity of the connections of contact segments and the associated fastening sections.
Disclosure of the Invention Technical Object The object of an aspect of the present invention, therefore, is to provide a commutator in which droplets of solder that overhang on the sides of the fastening sections are avoided, without reducing the quantity of solder used.
Technical Solution The present invention is based on the idea of forming a recess, in particular an elongated recess in the fastening section of the segment support piece, which is preferably made of copper or a copper alloy, and/or in the underside of the contact segment which is preferably made of a carbon-graphite mixture, and which faces the fastening section, the recess being used as a solder barrier and preventing the solder from flowing - at least in some regions - over the circumferential edge of the fastening section or the contact segment. A solder-barrier recess of this type may easily be stamped or punched in the fastening section in the process of manufacturing the segment support piece. The depth and width of the solder-barrier recess should be sized in such a manner that a quantity of liquid solder may be accommodated that is sufficient to prevent the solder-barrier recess from overflowing.
The solder-barrier recess preferably completely limits a solder surface to be provided with solder during the connecting process. It is also feasible, however, to provide a solder-barrier recess to protect only those regions against the infusion of liquid solder that are at highest risk, in particular the air gaps which are situated in the circumferential direction between two adjacent contact segments.
If the commutator is designed as a flat commutator having a flat brush running surface, the fastening section being formed by a radial section of the segment support piece, it is advantageous to situate the solder-barrier recess at least in a radially outer region of the fastening section in order to prevent liquid solder from escaping on the circumferential side of the commutator.
To realize the largest possible solder surface and, therefore, good robustness and electrical conductivity of the connections of contact segments and fastening sections, it is provided according to an advantageous development of the present invention to situate the solder-barrier recess close to the edge on the contact segment underside, and/or on the top side of the fastening section. The solder-barrier recess is preferably designed as a trough-like recess that is closed around the circumference.
To protect the solder connection between a contact segment and the associated fastening section from the harmful effects of heat, in particular during a hot-staking process to attach a winding wire to the winding connection hook of the associated segment support piece, it is advantageously provided in an embodiment of the present invention that a thermal barrier region having a reduced cross-sectional area is provided in a region between the winding connection hook and the fastening section. By reducing the effective cross-sectional area, the heat flow from the winding connection hook is hindered in the direction toward the fastening section and, therefore, in the direction toward the solder connection, thereby advantageously preventing negative effects of the hot-staking process on the solder connection.
Advantageously, the effective cross-sectional area in the thermal barrier region is reduced by the fact that at least one recess having a curved contour, preferably at least in sections, or a closed circumference, or is open at the edge is provided in the segment support piece.
The thermal barrier region is preferably formed in the thermal barrier region between two recesses which are separated in the circumferential direction, are open at the edges, and, in particular, are open and curved inward, thereby making only this small cross-sectional surface area available for heat flow in the direction toward the fastening section. Advantageously, the extension of the thermal barrier region in the circumferential direction at least approximately corresponds to the extension of the winding connection hook in the circumferential direction.
An expedient development of the present invention provides even better thermal protection. A metallic punched-bent part which is made of copper in particular, and which includes adjacent segment support pieces in the circumferential direction are used to manufacture the commutator. A solder-barrier recess is preferably provided in each of these segment support pieces. Every segment support piece includes a winding connection hook and a fastening section for fixing a contact segment. Every two adjacent segment support pieces are connected to one another via a segment which is oriented in the circumferential direction and is preferably curved. Otherwise, only an air gap is situated between the adjacent segment support pieces. As a whole, all of the segments form a connection having an annular shape. According to the present invention, it is now provided that this annular connection is situated as far as possible from the winding connection hooks, preferably in the region of the exposed end of the fastening sections that are far from the winding connection hooks. The situation is as 5 follows. As the manufacture of the commutator continues, in a first step, a contact disk is soldered to the fastening sections. Next, the component which is composed of the metallic punched-bent part and the contact disk which is preferably composed of carbon or a carbon-graphite mixture is partially covered, via injection molding with a coating of an insulating material, preferably a pressed material, in particular a duroplast with reinforcing element such as glass fibers or glass fiber beads. The metallic sides of the segment support pieces that face one another are also provided with a coating applied via injection molding. To electrically insulate the segment support pieces from one another, in a subsequent step, the contact disk must be subdivided into individual contact segments. Moreover, all connecting segments between the segment support pieces must be removed. This is carried out, e.g. in a sawing process in which the width of the saw or the saw blade is preferably smaller than the air gap between two adjacent segment support pieces. After the connecting segments are separated, two exposed metal surfaces remain on each segment support piece, which are not insulated against the hub body, and via which heat may "flow into" the segment support piece or its fastening section particularly easily, thereby negatively affecting the solder connection to the associated contact segment. Due to the largest possible separation, according to the present invention, of the connecting segments (and, therefore, the exposed metal surfaces) from the winding connection hooks which are heating during the hot-staking process, a minimal quantity of heat is introduced into the associated fastening section via these exposed areas, which advantageously affects the solder connection between the fastening section and the contact segment.
The present invention relates not only to the fully-assembled commutator, but also to the annular punched-bent part which is made of copper or a copper alloy in particular, and its manufacture, in which the connecting segments between the individual segment support pieces are situated as far as possible from the winding connection hooks.
5a In accordance with an aspect of the invention, there is provided a commutator comprising interspaced contact segments which form a brush running surface, each contact segment being soldered to a fastening section of a metallic segment support piece, and comprising a hub body composed of an electrically insulating material which supports the interspaced segment support pieces, each of which is provided with a winding connection hook, wherein at least one solder-barrier recess is formed in at least one of (a) an upper side of at least one of the fastening sections and facing one of the contact segments, and (b) an underside of at least one of the contact segments and facing one of the fastening sections and wherein the solder barrier recess extends at least approximately in a circumferential direction and is situated axially between a solder surface and the winding connection hook.
Brief Description of the Drawing Further advantages, features, and details of the present invention result from the description of preferred embodiments, below, and with reference to the drawing, which shows:
Figure 1 a perspective view of a commutator which is designed as a flat commutator, Figure 2 a punched-bent part for manufacturing a commutator, and Figure 3 a cross-sectional partial view of the punched-bent part along the line of intersection A-A in Figure 2.
Embodiments of the Invention Identical components and components having the same functionality are labelled with the same reference numerals in the figures.
The figures show a commutator 1 which is designed as a flat commutator for an electrical machine (not depicted) which is otherwise known. The present invention may also be realized, of course, in a commutator having a brush running surface on the jacket surface. Commutator 1 is designed symmetrical around longitudinal axis L, and, in the installed state, it is non-rotatably mounted on a not-shown armature shaft which extends through a centric receiving opening in the commutator.
Commutator 1 includes a hub body 3 which is designed as a plastic injection-molded part, and which includes several interspaced segment support pieces 4 which are made of copper and are distributed around the circumference. Every segment support piece 4 includes, in the case of commutator 1 which is designed as a flat commutator, a plate-shaped fastening section 5 which is designed as a radial section and is shown in figure 2, and it includes an axial section 6 which extends at a 90 angle to fastening section 5;
a winding connection hook 7 is provided on the end of axial section 6 that faces away from fastening section 5. Winding connection hooks 7 are bent in the direction of a flat brush running surface 8 situated on the end face.
Brush running surface 8 is formed by a plurality of contact segments 9 which are made of carbon or a carbon-graphite mixture. A fastening section 5 of a segment support piece 4 is assigned to every contact segment 9 which tapers inwardly in the radial direction, every contact segment 9 being soldered to associated fastening section 5 in a fixed, electrically conducting manner. Contact segments 9 are metallized in a known manner on the side facing fastening sections 5.
In the circumferential direction, every two adjacent contact segments 9 are electrically insulated from one another via an air gap 10 which extends in the radial direction.
Figure 2 shows a punched-bent part 11 (base) which is required to manufacture the commutator. Punched-bent part 11 includes a plurality of segment support pieces 4 which are situated adjacent to one another in the circumferential direction, every two adjacent segment support pieces 4 being connected to one another via a connecting segment 12. A contact disk (not depicted) which will eventually become contact segments 12 is soldered onto punched-bent part 11; next, the unit comprising punched-bent part 11 and the contact disk is partially enclosed in hub-body material which is applied via injection molding, wherein, e.g. sides 13, 14 of fastening sections 5 which face one another are provided with a coating applied via injection molding. To electrically insulate individual segment support pieces 4 from one another, connecting segments 12 must be separated from one another in a further step, in particular using a sawing process.
To ensure that the resultant, exposed metal surfaces are situated as far as possible from winding connection hooks 7, connecting segments 12 are situated on the inner radius of punched-bent part 12. Only anchoring claws which point downward at an angle, and which may be eliminated if so desired, extend past connecting segments 12 inwardly in the radial direction and at an angle.
As shown in figures 2 and 3, a solder-barrier recess 16 is punched into every fastening section 5, which is used to prevent solder from flowing over edge 17 of fastening sections 5. Solder-barrier recess 16 is a trough-like recess which is closed around the circumference and has an essentially triangular contour, having a depth t and a width b.
The distance of the solder-barrier recess 16 from edge 17 is approximately one to two times the width b of solder-barrier recess 16.
On the upper - relative to the plane of the drawing - end of axial sections 6, i.e. directly adjacent to particular fastening section 5, a thermal barrier region 18 is provided which hinders the transfer of heat from winding connection hooks 7 in the direction of fastening section 6, in particular during a hot-staking process to attach a winding wire.
The cross-sectional area of thermal barrier region 18 is reduced compared to the cross-sectional area of axial section 6 in a region near the winding connection hook 7. The cross-sectional area is reduced using sets of two diametrically opposed recesses 19, 20 which are open at the end, and which have curved contours on their inner ends which face one another. Extension x of thermal barrier region 18 in the circumferential direction at least approximately corresponds to extension x of associated winding connection hook 7 in the circumferential direction.
Figure 1 a perspective view of a commutator which is designed as a flat commutator, Figure 2 a punched-bent part for manufacturing a commutator, and Figure 3 a cross-sectional partial view of the punched-bent part along the line of intersection A-A in Figure 2.
Embodiments of the Invention Identical components and components having the same functionality are labelled with the same reference numerals in the figures.
The figures show a commutator 1 which is designed as a flat commutator for an electrical machine (not depicted) which is otherwise known. The present invention may also be realized, of course, in a commutator having a brush running surface on the jacket surface. Commutator 1 is designed symmetrical around longitudinal axis L, and, in the installed state, it is non-rotatably mounted on a not-shown armature shaft which extends through a centric receiving opening in the commutator.
Commutator 1 includes a hub body 3 which is designed as a plastic injection-molded part, and which includes several interspaced segment support pieces 4 which are made of copper and are distributed around the circumference. Every segment support piece 4 includes, in the case of commutator 1 which is designed as a flat commutator, a plate-shaped fastening section 5 which is designed as a radial section and is shown in figure 2, and it includes an axial section 6 which extends at a 90 angle to fastening section 5;
a winding connection hook 7 is provided on the end of axial section 6 that faces away from fastening section 5. Winding connection hooks 7 are bent in the direction of a flat brush running surface 8 situated on the end face.
Brush running surface 8 is formed by a plurality of contact segments 9 which are made of carbon or a carbon-graphite mixture. A fastening section 5 of a segment support piece 4 is assigned to every contact segment 9 which tapers inwardly in the radial direction, every contact segment 9 being soldered to associated fastening section 5 in a fixed, electrically conducting manner. Contact segments 9 are metallized in a known manner on the side facing fastening sections 5.
In the circumferential direction, every two adjacent contact segments 9 are electrically insulated from one another via an air gap 10 which extends in the radial direction.
Figure 2 shows a punched-bent part 11 (base) which is required to manufacture the commutator. Punched-bent part 11 includes a plurality of segment support pieces 4 which are situated adjacent to one another in the circumferential direction, every two adjacent segment support pieces 4 being connected to one another via a connecting segment 12. A contact disk (not depicted) which will eventually become contact segments 12 is soldered onto punched-bent part 11; next, the unit comprising punched-bent part 11 and the contact disk is partially enclosed in hub-body material which is applied via injection molding, wherein, e.g. sides 13, 14 of fastening sections 5 which face one another are provided with a coating applied via injection molding. To electrically insulate individual segment support pieces 4 from one another, connecting segments 12 must be separated from one another in a further step, in particular using a sawing process.
To ensure that the resultant, exposed metal surfaces are situated as far as possible from winding connection hooks 7, connecting segments 12 are situated on the inner radius of punched-bent part 12. Only anchoring claws which point downward at an angle, and which may be eliminated if so desired, extend past connecting segments 12 inwardly in the radial direction and at an angle.
As shown in figures 2 and 3, a solder-barrier recess 16 is punched into every fastening section 5, which is used to prevent solder from flowing over edge 17 of fastening sections 5. Solder-barrier recess 16 is a trough-like recess which is closed around the circumference and has an essentially triangular contour, having a depth t and a width b.
The distance of the solder-barrier recess 16 from edge 17 is approximately one to two times the width b of solder-barrier recess 16.
On the upper - relative to the plane of the drawing - end of axial sections 6, i.e. directly adjacent to particular fastening section 5, a thermal barrier region 18 is provided which hinders the transfer of heat from winding connection hooks 7 in the direction of fastening section 6, in particular during a hot-staking process to attach a winding wire.
The cross-sectional area of thermal barrier region 18 is reduced compared to the cross-sectional area of axial section 6 in a region near the winding connection hook 7. The cross-sectional area is reduced using sets of two diametrically opposed recesses 19, 20 which are open at the end, and which have curved contours on their inner ends which face one another. Extension x of thermal barrier region 18 in the circumferential direction at least approximately corresponds to extension x of associated winding connection hook 7 in the circumferential direction.
Claims (12)
1. A commutator comprising interspaced contact segments which form a brush running surface, each contact segment being soldered to a fastening section of a metallic segment support piece, and comprising a hub body composed of an electrically insulating material which supports the interspaced segment support pieces, each of which is provided with a winding connection hook, wherein at least one solder-barrier recess is formed in at least one of (a) an upper side of at least one of the fastening sections and facing one of the contact segments, and (b) an underside of at least one of the contact segments and facing one of the fastening sections and wherein the solder barrier recess extends at least approximately in a circumferential direction and is situated axially between a solder surface and the winding connection hook.
2. The commutator as recited in claim 1, wherein the solder barrier recess encloses a soldering surface at least partially.
3. The commutator as recited in claim 2 wherein the solder barrier recess encloses the soldering surface completely.
4. The commutator as recited in any one of the claims 1-3, wherein the solder barrier recess is situated close to at least one of an edge on the contact segment underside and the fastening section top side.
5. The commutator as recited in any one of the claims 1-4, wherein the cross-sectional surface of at least one of the segment support pieces is smaller in a thermal barrier region situated between the fastening section and the winding connection hook than it is in a region between the thermal barrier region and the winding connection hook.
6. The commutator as recited in claim 5, wherein the cross-sectional area in the thermal barrier region is reduced by at least one recess in the segment support piece, which has a curved contour.
7. The commutator as recited in claim 6 wherein each of the at least one recess has a curved contour in sections or has at least one of a closed circumference or is open at an edge.
8. The commutator as recited in any one of claims 5-7, wherein two recesses which are open at the edge and are separated in the circumferential direction are provided.
9. The commutator as recited in any one of the claims 5-8, wherein the extension of the thermal barrier region in the circumferential direction correspondings at least approximately to the extension of the winding connection hook in the circumferential direction.
10. The commutator as recited in any one of claims 1 through 9,
11 wherein every side of the fastening section that faces the adjacent fastening sections is provided with a coating applied via injection molding, except for an exposed metal surface of the hub body, the exposed metal surfaces being situated at a distance from the axial section of the segment support piece on which the winding connection hook is installed.
11. The commutator as recited in claim 10, wherein the exposed metal surfaces are situated in the region of the exposed end of the fastening section.
11. The commutator as recited in claim 10, wherein the exposed metal surfaces are situated in the region of the exposed end of the fastening section.
12. An annular punched-bent part for manufacturing a commutator as recited in any one of claims 1-11, having several segment support pieces which are situated next to one another in the circumferential direction, and each of which includes a winding connection hook, two adjacent segment support pieces being connected to one another in each case via a connecting segment, wherein the connecting segments are situated on the end region of the segment support pieces facing away from the winding connection hook.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102006046669.1 | 2006-09-29 | ||
| DE102006046669A DE102006046669A1 (en) | 2006-09-29 | 2006-09-29 | Commutator has contact segments, dissociated from each other, forming commutator surface, where each of segments is soldered with mounting section of metallic segment support part, and segment is provided with hub body |
| PCT/EP2007/057940 WO2008040586A1 (en) | 2006-09-29 | 2007-08-01 | Commutator for an electrical machine |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2664436A1 CA2664436A1 (en) | 2008-04-10 |
| CA2664436C true CA2664436C (en) | 2012-04-17 |
Family
ID=38434423
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2664436A Active CA2664436C (en) | 2006-09-29 | 2007-08-01 | Commutator for an electrical machine |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US8269394B2 (en) |
| EP (1) | EP2076945B1 (en) |
| CA (1) | CA2664436C (en) |
| DE (1) | DE102006046669A1 (en) |
| MX (1) | MX2009003341A (en) |
| WO (1) | WO2008040586A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104979731A (en) * | 2014-04-02 | 2015-10-14 | 德昌电机(深圳)有限公司 | Motor commutator, carbon-containing product and manufacturing method therefor |
| DE102015202349A1 (en) | 2014-12-16 | 2016-06-16 | Volkswagen Aktiengesellschaft | Circuit arrangement of an electrical machine with asymmetric cross-section in a connecting portion |
| CN107453177B (en) * | 2016-05-30 | 2023-04-28 | 深圳市凯中精密技术股份有限公司 | Copper shell, commutator with copper shell and manufacturing method of commutator |
Family Cites Families (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4028420A1 (en) * | 1990-09-07 | 1992-03-12 | Kautt & Bux Kg | PLANKOMMUTATOR AND METHOD FOR THE PRODUCTION THEREOF |
| JP3313509B2 (en) * | 1994-04-25 | 2002-08-12 | 株式会社ミツバ | Commitator |
| KR100332318B1 (en) * | 1998-02-02 | 2002-04-12 | 오카메 히로무 | Commutator and method of manufacturing the same |
| DE19926900A1 (en) * | 1999-06-12 | 2000-12-21 | Kirkwood Ind Gmbh | Process for producing a flat commutator and commutator produced by this process |
| DE19956844A1 (en) * | 1999-11-26 | 2001-06-13 | Kolektor D O O | Flat commutator, process for its manufacture and blank and carbon disc for use in its manufacture |
| US6525445B2 (en) * | 2000-04-13 | 2003-02-25 | Denso Corporation | Plane commutator and method of manufacturing the same |
| US6784589B1 (en) * | 2000-05-25 | 2004-08-31 | Sugiyama Seisakusyo Co. Ltd. | Plane carbon commutator |
| MXPA05006707A (en) * | 2000-05-31 | 2005-09-08 | Kolektor Group Doo | Method of producing a flat commutator and a flat commutator produced according to said method. |
| DE10042512A1 (en) * | 2000-08-30 | 2002-03-28 | Bosch Gmbh Robert | hook commutator |
| GB0104915D0 (en) * | 2001-02-28 | 2001-04-18 | Johnson Electric Sa | A planar carbon segment comutator |
| DE102004003146B4 (en) * | 2003-01-22 | 2023-08-24 | Aisan Kogyo Kabushiki Kaisha | Motor, fuel pump, commutator and method of making a commutator |
| US7419084B2 (en) * | 2004-11-24 | 2008-09-02 | Xerox Corporation | Mounting method for surface-mount components on a printed circuit board |
-
2006
- 2006-09-29 DE DE102006046669A patent/DE102006046669A1/en not_active Withdrawn
-
2007
- 2007-08-01 CA CA2664436A patent/CA2664436C/en active Active
- 2007-08-01 WO PCT/EP2007/057940 patent/WO2008040586A1/en active Application Filing
- 2007-08-01 MX MX2009003341A patent/MX2009003341A/en not_active Application Discontinuation
- 2007-08-01 US US12/443,592 patent/US8269394B2/en not_active Expired - Fee Related
- 2007-08-01 EP EP07788111.8A patent/EP2076945B1/en not_active Not-in-force
Also Published As
| Publication number | Publication date |
|---|---|
| DE102006046669A1 (en) | 2008-04-03 |
| WO2008040586A1 (en) | 2008-04-10 |
| MX2009003341A (en) | 2009-04-14 |
| CA2664436A1 (en) | 2008-04-10 |
| EP2076945B1 (en) | 2017-03-22 |
| US8269394B2 (en) | 2012-09-18 |
| US20100019615A1 (en) | 2010-01-28 |
| EP2076945A1 (en) | 2009-07-08 |
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| Date | Code | Title | Description |
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| EEER | Examination request |